The problem of preparing a ternary powder mixture, which was meant to fabricate sintered heterophase composite, and consisted of micro- and two nanosized powders, was analyzed. The microsized powder was a pure magnesium, and as nanocomponents, a silicon powder (nSi) and carbon nanotubes (CNTs) with 2% and 1% volume fractions, respectively, were applied. The powder mixtures were prepared using ultrasonic and mechanical mixing in technological fluid, and four mixing variants were applied. The morphology of the powder mixtures was characterized with scanning electron microscopy (SEM), and then, composite sinters were fabricated in a vacuum with hot temperature pressing at 580 °C under 15 MPa pressure, using a Degussa press. The reaction between the nSi and the Mg matrix, which caused the creation of the Mg2Si phase in the fabricated Mg-Mg2Si-CNT composite, was confirmed with X-ray diffraction (XRD). The porosity and hardness of the composite sinters were examined, and optical microscopy (OM) and quantitative image analyses were carried out to characterize the microstructure of the composites. In the manufacturing process of the Mg-nSi-CNT mixtures, the best results were the following: first separate de-agglomeration of nanocomponents, then their common mixing, and finally, the deposition of nanocomponents at the surface of the microsized magnesium powder. The applied procedure ensured the uniform layer formation of de-agglomerated nanocomponents on the Mg powder, without re-agglomerated nSi and CNTs. Moreover, this type of powder mixture morphology allows to obtain sinters with lower porosity and higher hardness, which is accompanied by precipitation of a finer Mg2Si phase. In the Mg-Mg2Si-CNT composite, the carbon phase was present, and it was located in the magnesium matrix and in silicide.

In this study, we present a new composite material that was developed using the pressure infiltration method. In this composite, carbon reinforcement in the form of an open-celled rectangular foam (C of ) was applied, and pure magnesium with two commercial magnesium cast alloys (AZ31, RZ5) was used as the matrix. We examined the microstructure (LM, SEM + EDS) of composites as well as the density, porosity, hardness, compressive strength, flexural strength and tribological properties in dry conditions. It was revealed that the chemical composition of the matrix had a significant impact on the macrostructure, microstructure and properties of the composite. The matrix with rare elements (RZ5) induced poor infiltration of C of and physicochemical degradation of the reinforcement, while pure magnesium ensured good infiltration, a stable friction coefficient and low wear. For the AZ31 alloy, the effects of infiltration were good; however, an increase in the tribological properties was not observed. Compared with the as-cast matrix materials, the presence of carbon foam in both pure Mg and AZ31 alloy induced an increase in compressive strength and stiffness as well as a decrease in flexural strength. Furthermore, SEM examination of the fractured and wear surfaces microstructure showed structural effects' dependence on the matrix composition.

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The effects of severe plastic deformation (SPD) with a forward-backward rotating die (KOBO extrusion) on pure magnesium, in the form of cold-compacted powder, sintered powder, or cast ingots as reference, were examined. This method is known to reinforce metals, but the role of the initial form of magnesium applied in the fabrication of metal-based rods, as well as related phenomena, has not been characterized until now. The problem is important in the potential processing of commercial metal powders, the recycling of metal shavings, and the fabrication of metal matrix composites with discontinuous reinforcing phases. In the presented experiments, rods of 8 mm in diameter and 400 mm in length were obtained, and the structural effects induced by KOBO that occurred on a macro- and microscale on the surface and cross sections were characterized. Changes in the size and orientation of α-Mg crystallites were determined by XRD. The porosity, hardness, tensile strength, and compressive strength were measured, and the mechanisms of decohesion dependent on starting metal form were analyzed. After KOBO extrusion, significant differences were observed in the microstructure and properties between the materials derived from cold-compacted powder, sintered powder, and reference cast magnesium. Due to the application of KOBO, apart from α-Mg grain refinement, the MgO derived from the initial powder’s surface was refined to fine regular particles surrounded by magnesium. Their bands curved in the perpendicular plane and were oriented with the extrusion direction of the formed network, which augmented some mechanical properties and changed the decohesion mechanism. The conducted experiments revealed that before extrusion by KOBO, the magnesium powder required sintering under pressure.

The new in situ fabrication process for Mg-Mg2Si composites composed of interpenetrating metal/intermetallic phases via powder metallurgy was characterized. To obtain the designed composite microstructure, variable nanosilicon ((n)Si) (i.e., 2, 4, and 6 vol.% (n)Si) concentrations were mixed with magnesium powders. The mixture was ordered using a sonic method. The powder mixture morphologies were characterized using scanning electron microscopy (SEM), and heating and cooling-induced thermal effects were characterized using differential scanning calorimetry (DSC). Composite sinters were fabricated by hot-pressing the powders under a vacuum of 2.8 Pa. Shifts in the sintering temperature resulted in two observable microstructures: (1) the presence of Mg2Si and MgO intermetallic phases in α-Mg (580 °C); and (2) Mg2Si intermetallic phases in the α-Mg matrix enriched with bands of refined MgO (640 °C). Materials were characterized by light microscopy (LM) with quantitative metallography, X-ray diffraction (XRD), open porosity measurements, hardness testing, microhardness testing, and nanoindentation. The results revealed that (n)Si in applied sintering conditions ensured the formation of globular and very fine Mg2Si particles. The particles bonded with each other to form an intermetallic network. The volume fraction of this network increased with (n)Si concentration but was dependent on sintering temperature. Increasing sintering temperature intensified magnesium vaporization, affecting the composite formation mechanism and increasing the volume fraction of silicide.